Waste-to-Fuels: Pyrolysis of Low-Density Polyethylene Waste in the Presence of H-ZSM-11

Experimental investigation of products from thermal treatment of real-world mixed single-use and multi-layered waste plastics

The usage and disposal of highly abundant single-use and multilayered plastics contribute to significant ecological problems. The thermochemical recovery of these plastics to useful products and chemicals provides opportunity for positive economic and environmental impacts. Most previous research use idealised and unrepresentative feedstocks. To address this, various mixed waste plastics collected from the rejected fraction of a municipal waste recovery facility in Ghana were pyrolyzed at varying temperatures of 450, 500 and 550 °C and their yields compared. The obtained chemical products were analysed using several different techniques. Energy and carbon balances of the processes were produced using the CHNS and energy content of the oil fraction and the compositional results of the pyrolysis gas fraction, the latter of which was measured by Gas Chromatography Thermal Conductivity Detection (GC-TCD). The oils were further assessed via Gas Chromatography Mass Spectrometry (GC-MS) to identify the available valuable compounds. The formed oil contained approximately 40% light hydrocarbons (C6 - C11), 18% middle hydrocarbons (C11 - C16) and 42% heavy hydrocarbon compounds (C16+). The optimal oil yield of 65.9 ± 0.5% and low heating value of 44.7 ± 0.1 MJ/kg for single-use plastics were recorded at highest heating temperatures of 550 and 500 °C, respectively. The findings provide indication that pyrolysis is a fitting solution for energy recovery from waste plastics.

Assessing the Settling Velocity of Biofilm-Encrusted Microplastics: Accounting for Biofilms as an Equivalent to Surface Roughness

While it is well established that a biofilm contributes to the sinking of plastics, the underlying mechanisms of how it influences the vertical transport of plastics have not been well explained. In this context, our study dives into the intricate effects of biofouling on the settling velocity (Ws) of microplastics (MPs) within the fluid. We adopt the perspective that the biofilm is a form of surface roughness impacting the drag coefficient (Cd) and vertical settling of MPs. By advancing the biofouling process model, we simulate the temporal variations of density and biofilm thickness of biofouled floating MPs, accounting for realistic parameters and assuming a layer-by-layer growth of biofilm on plastisphere surfaces. MPs of polyethylene (PE) exhibit a quicker initiation of descent compared to their polypropylene (PP) counterparts. Furthermore, leveraging computational fluid dynamics (CFD) simulation, the method to predict the Cd of spherical MPs with surface roughness is established. By treating the thickness of the biofilm as roughness height, an explicit method to predict the Ws of biofouled MPs is derived. The settling experiments for biofouled MPs conducted not only support the combination of the biofouling model and the explicit method to predict the Ws of biofouled MPs but also enhance the prediction accuracy by introducing a ratio parameter Co to better relate the equivalent surface roughness height (k) to the biofilm thickness (σ), i.e., k = Co·σ, where the recommended value of Co for spherical PP and PE MPs is between 0.5 to 0.8. This study, thus, provides new insights into the dynamics of biofouled MPs in hydraulic ecosystems.

Sustainable ethylene production: Recovery from plastic waste via thermochemical processes

The concept of monomer recovery from plastic waste has recently gained broad interest in industry as a powerful strategy to reduce the environmental impacts of chemical production and plastic waste pollution. Herein, we focus on the ethylene recovery from plastic waste via thermochemical pathways, such as pyrolysis, gasification, and steam cracking of pyrolysis oil derived from plastic waste. Ethylene recovery performance of different thermochemical conversion processes is evaluated and compared with respect to plastic waste types, process types, ethylene recovery yields, and process operating conditions. Based on the analysis of available data in earlier literature, future research is recommended to further enhance the viability of the thermochemical ethylene recovery technologies. This review is expected to offer a meaningful guideline on developing efficient platforms for the value-added monomer recovery from plastic waste through thermochemical conversion routes. It is also hoped that this review serves as a preliminary step to encourage the widespread adoption of thermochemical conversion-based ethylene recovery from plastic waste by industries.

Production of C5-C12 olefins by catalytic pyrolysis of low-density polyethylene with MCM-41 in CO2/N2

The current high volume of plastic waste, but low recycling rate, has led to environmental pollution and wasted energy. Greenhouse gas CO2 can facilitate thermal cracking to dehydrogenate waste plastics, and has potential value for producing olefins. In this work, the pyrolysis properties of low-density polyethylene (LDPE) were studied by thermogravimetric analysis and Py-GC/MS. The effect of the pyrolysis atmosphere, using N2 or CO2, with various MCM-41 catalyst ratios on pyrolysis product distribution, were investigated. The experimental results show that the olefin selectivity under a N2 atmosphere was from 30.32 % to 44.66 % which increased as the MCM-41 catalyst was increased. Under a CO2 atmosphere, the olefin selectivity reached a maximum of 60.39 %. The Boudouard reaction was also enhanced by the introduction of CO2. The carbon content of the subdivided olefins showed that in CO2, the promotion of C5-C12 olefins was relatively weak when non-catalyzed or at low catalytic ratios, but increased significantly at higher MCM-41 catalyst ratios. With a ratio of LDPE: MCM-41 = 5:4, the CO2 atmosphere showed the greatest promotion of C5-C12 olefins over N2, with an increase of 14.66 % compared to N2, representing a 48.54 % yield of the liquid product. Producing C5-C12 olefins under these conditions maximized energy efficiency. These results show that catalytic pyrolysis of LDPE under a CO2 atmosphere has great potential to produce C5-C12 olefins, which can be used to produce high-value chemicals such as naphtha and gasoline. This opens new opportunities for the chemical recycling of plastic waste.

Conversion of Polyethylene to High-Yield Fuel Oil at Low Temperatures and Atmospheric Initial Pressure

The transformation of waste plastics into fuels via energy-efficient and low-cost pyrolysis could incentivize better waste plastic management. Here, we report pressure-induced phase transitions in polyethylene, which continue to heat up without additional heat sources, prompting the thermal cracking of plastics into premium fuel products. When the nitrogen initial pressure is increased from 2 to 21 bar, a monotonically increasing peak temperature is observed (from 428.1 °C to 476.7 °C). At 21 bar pressure under different atmosphere conditions, the temperature change driven by high-pressure helium is lower than that driven by nitrogen or argon, indicating that phase transition is related to the interaction between long-chain hydrocarbons and intercalated high-pressure medium layers. In view of the high cost of high-pressure inert gases, the promotion or inhibition effect of low-boiling hydrocarbons (transitioning into the gaseous state with increasing temperature) on phase transition is explored, and a series of light components are used as phase transition initiators to replace high-pressure inert gases to experiment. The reason that the quantitative conversion of polyethylene to high-quality fuel products is realized through the addition of 1-hexene at a set temperature of 340 °C and the initial atmospheric pressure. This discovery provides a method for recycling plastics by low energy pyrolysis. In addition, we envisage recovering some of the light components after plastic pyrolysis as phase change initiators for the next batch of the process. This method is able to reduce the cost of light hydrocarbons or high-pressure gas insertion, reduce heat input, and improve material and energy utilization.

Preparation of sodium silicate/red mud-based ZSM-5 with glucose as a second template for catalytic cracking of waste plastics into useful chemicals

ZSM-5 was economically synthesized with red mud (RM) and industrial sodium silicate (ISS) in a tetrapropylammonium bromide (TPABr)-glucose dual-template system. The roles of glucose, Fe and Ca in RM on the formation of ZSM-5 were investigated. The catalytic performances of the resultant ZSM-5 were tested by cracking waste plastics. It was found that the formation of ZSM-5 was attributed to a synergistic effect between TPABr and glucose. The addition of glucose decreased the pH value in the crystallization solution and thus promoted the crystallization effect. Glucose acted as a hard template to generate mesopores. Fe atoms were partly distributed in the framework and partly adsorbed in the pores of ZSM-5, and helped to generate more Lewis acid sites. Ca atoms were mainly adsorbed in the pores of ZSM-5, and showed an inhibitory effect on the formation of zeolites. The synthesized ZSM-5 showed a weakly acidic and mesoporous structure and achieved an enhanced effect on producing gaseous products (gas yield: 85.3%), especially light olefins (C^{[double bond, length as m-dash]} _2-4) (selectivity: 77.1%) from cracking of low density polyethylene at 500 °C. The long-term cracking experiment showed that the synthesized ZSM-5 is superior in converting waste plastics to light olefins (ethylene and propene) than the commercial ZSM-5.

A Low-Cost Porous Polymer Membrane for Gas Permeation

In this work, an efficient technique was used to produce porous membranes for different applications. Polyethylene (PE) was selected for the matrix, while corn starch (CS) was used to create the porous structure via leaching. The membranes were produced by continuous extrusion (blending)–calendering (forming) followed by CS leaching in a 20% aqueous acetic acid solution at 80 °C. A complete characterization of the resulting membranes was performed including morphological and mechanical properties. After process optimization, the gas transport properties through the membranes were determined on the basis of pure gas permeation including CH₄, CO₂, O₂, and N₂ for two specific applications: biogas sweetening (CH₄/CO₂) and oxygen-enriched air (O₂/N₂). The gas separation results for ideal permeability and selectivity at 25 °C and 1.17 bar (17 psi) show that these membranes are a good starting point for industrial applications since they are low-cost, easy to produce, and can be further optimized.

Pyrolysis of long chain hydrocarbon-based plastics via self-exothermic effects: The origin and influential factors of exothermic processes

Converting plastic wastes into value-added products through energy-efficient pyrolysis is essential, and it requires lower pyrolysis temperatures and shorter processing times than that of other processes. An exothermic phenomenon was observed during the process high-pressure polyethylene pyrolysis. It was proven for the first time that the exotherm is caused by a pressure-induced phase transition, in which colossal heat release can be driven by relatively small pressures. A large temperature change (> 100 °C) leads to the deep cracking of polyethylene, although the set temperature is far lower than the required temperature for thermal cracking. Importantly, the heat input stops immediately when the set temperature is reached; thus, the external heating time is short. Polyethylene can be completely converted into liquid products in ~90 wt% yield and with a small number of gases. The self-exothermic phase transition only occurs within a certain range of material thickness, which is related to the corresponding phase behavior. In the self-exothermic pyrolysis process, with an increase in the thickness of polyethylene, the proportion of low-value olefins in oil products decreases gradually, while alkanes, isoalkanes and aromatics show an increasing trend, making the product composition closer to the fuel standard. This work provides a viable approach for plastic recycling at low pyrolysis temperatures and short external heating times with the help of a self-exothermic phase transition in the absence of a catalyst.

Suppression of the hazardous substances in catalytically upgraded bio-heavy oil as a precautious measure for clean air pollution controls

Bio-heavy oil (BHO) is a renewable fuel, but its efficient use is problematic because its combustion may emit hazardous air pollutants (e.g., polycyclic aromatic hydrocarbon (PAH) compounds, NO_x, and SO_x). Herein, catalytic fast pyrolysis over HZSM-5 zeolite was applied to upgrading BHO to drop-in fuel-range hydrocarbons with reduced contents of hazardous species such as PAH compounds and N- and S-containing species (NO_x and SO_x precursors). The effects of HZSM-5 desilication and linear low-density polyethylene (LLDPE) addition to the feedstock on hydrocarbon production were explored. The apparent activation energy for the thermal decomposition of BHO was up to 37.5% lowered by desilicated HZSM-5 (DeHZSM-5) compared with HZSM-5. Co-pyrolyzing LLDPE with BHO increased the content of drop-in fuel-range hydrocarbons and decreased the content of PAH compounds. The DeHZSM-5 was effective in producing drop-in fuel-range hydrocarbons from a mixture of BHO and LLDPE and suppressing the formation of N- and S-containing species and PAH compounds. The DeHZSM-5 enhanced the hydrocarbon production by up to 58.5% because of its enhanced porosity and high acid site density compared to its parent HZSM-5. This study experimentally validated that BHO can be upgraded to less hazardous fuel via catalytic fast co-pyrolysis with LLDPE over DeHZSM-5.

Single-Use Disposable Waste Upcycling via Thermochemical Conversion Pathway

Herein, the pyrolysis of two types of single-use disposable waste (single-use food containers and corrugated fiberboard) was investigated as an approach to cleanly dispose of municipal solid waste, including plastic waste. For the pyrolysis of single-use food containers or corrugated fiberboard, an increase in temperature tended to increase the yield of pyrolytic gas (i.e., non-condensable gases) and decrease the yield of pyrolytic liquid (i.e., a mixture of condensable compounds) and solid residue. The single-use food container-derived pyrolytic product was largely composed of hydrocarbons with a wide range of carbon numbers from C₁ to C₃₂, while the corrugated fiberboard-derived pyrolytic product was composed of a variety of chemical groups such as phenolic compounds, polycyclic aromatic compounds, and oxygenates involving alcohols, acids, aldehydes, ketones, acetates, and esters. Changes in the pyrolysis temperature from 500 °C to 900 °C had no significant effect on the selectivity toward each chemical group found in the pyrolytic liquid derived from either the single-use food containers or corrugated fiberboard. The co-pyrolysis of the single-use food containers and corrugated fiberboard led to 6 times higher hydrogen (H₂) selectivity than the pyrolysis of the single-use food containers only. Furthermore, the co-pyrolysis did not form phenolic compounds or polycyclic aromatic compounds that are hazardous environmental pollutants (0% selectivity), indicating that the co-pyrolysis process is an eco-friendly method to treat single-use disposable waste.